tis review 13 dec. 2000 bill elliott ir absorber status1 bill elliott lbnl presented at the tis...
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TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 1
IR ABSORBER STATUS
Bill Elliott
LBNL
Presented at the
TIS SAFETY REVIEW
13 Dec. 2000
Berkeley,CA
brookhaven - fermilab - berkeleyUS LHC ACCELERATOR PROJECT
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 2
ENGINEERING DESIGN
TAN - Neutral Absorber
TAS - Front Quadrupole Absorber
FABRICATION PLAN
Sequence of Production
SAFETY ISSUES
Lifting and Handling
Surface Temperatures during Vacuum Bakeout
Seismic Stability
Radiation
IMPLEMENTATION OF SAFETY MoU
Engineering Design Review (EDR)
Production Readiness Review (PRR)
IR ABSORBERS - OVERVIEW
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 3
IR ABSORBERS - TAN DESIGN
Lower base plate
Upper base plate
Absorber box
Junction box
Side shielding (2)
Upper shielding
Marble
Beam tubevacuum chamber
Jacks (3)
Copper bars
Beam tube support bracket The steel shielding is
a pinned structure withfour through bolts fortransport.
Through bolt
The TAN consists of two major sub-assemblies: - Absorber Box - Steel Shielding.
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 4
TAN DESIGN/ENGINEERING SUMMARY
- TAN requirements, parameters and interfaces have been defined
- Interface and Functional Specifications have been approved by CERN
- TAN engineering calculations for tolerances, stress/deflection, bakeout
and cooling have been completed.
- Drawing details completed and released
- Quality control, Acceptance, Fabrication, Procurement plansdeveloped and reviewed at PRR.
- FEA thermal model completed to verify analytic calculations
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 5
IR ABSORBERS - TAS LOCATION (ATLAS)
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 6
TAS ASSEMBLY (EXPLODED)
HEATER,THERMOCOUPLES
LOWER COPPER CLAMSHELL
UPPER COPPER CLAMSHELL
COPPER BEAM TUBE34 mm ID40 mm ID
SUPPORT CRADLE (ASSY ONLY)
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 7
• TAS requirements, parameters and interfaces have been defined.
• TAS engineering completed– calculations for tolerances, stress/deflection, bakeout and cooling– 3D Pro-Engineer model– Safety issues documented.
• Detailed design drawings nearly completed.
• FEA thermal model needed to check analytic calculations.
TAS DESIGN/ENGINEERING SUMMARY
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 8
FABRICATION PLAN
IR Absorber PRR02 Nov 2000, LBNL
Bill ElliottTAN/TAS ASSEMBLY 9
BUILDING 60 Assembly- Stage 4
4 TAN-Base plate4 TAS- In test
Building 60•30 Ton overhead crane•Floor load capability•Office and Clean room•Open floor space
IR Absorber PRR02 Nov 2000, LBNL
Bill ElliottTAN/TAS ASSEMBLY 10
TAN/TAS SCHEDULE
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Bill ElliottIR ABSORBER STATUS 11
Lifting and HandlingSurface Temperatures during Vacuum BakeoutSeismic Stability
These items detailed in LBNL Engineering notes:TAN Safety Note M7090TAS Safety Note M7905
Radiation: Bill Turner is in contact with Grahm Stevenson
SAFETY RELATED DESIGN FEATURES
TIS Review13 Dec. 2000
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SAFETY - LIFTING AND HANDLING
TAN I.S.- 4.1 Safety Engineered Hoist Rings
Configuration:
3 sizes to be used:
- Four 11,000 kg rated Hoist Rings for lifting the
entire TAN assembly with a spreader beam.
- 7,000 kg rated Hoist Rings for lifting the 8 TAN
subassemblies.
- Two 400 kg rated Hoist Rings for lifting the
transport housing
TAN I.S.- 4.2 Subassembly Lifting Locations
Locations:
No. Subassembly Weight
(kg)
SubassemblyLength
(mm)
Permanent HoistRing Location *
(mm)
Additional Hoist
Ring Locations *
(mm)
1 Lower Base Plate 4900 3000 1500 600
2 Upper Base Plate 4900 3000 1500 600
3 Absorber Box 5000 3800 1900 240
4 Aisle Side Shielding 4100 3000 1500 600
5 Cryo Side Shielding 4100 3000 1500 600
6 Upper Shielding 5000 3000 1500 600
7 Aisle Side Marble 700 450 225
8 Cryo Side Marble 700 450 225
* Measured from either end of a subassembly.
TAS I.S.- 4. Rigging
4.1 Safety Engineered Hoist Rings
- Configuration:
- Size: 4200 kg
TAS I.S.- 4.2 Subassembly Lifting Locations
Locations:
Part or Assembly Weight
(kg)
Part/Assembly
Length
(mm)
AssemblyHoist RingLocation
X (mm)
AssemblyHoist RingLocation*
Y (mm)
PermanentHoist RingLocation
X (mm)
PermanentHoist RingLocation*
Y (mm)
Lower CopperClamshell - topside
1600 1800 190
-190
375
1425
Lower CopperClamshell -underside
1600 1800 0.0
0.0
280
1520
Upper CopperClamshell - topside
1600 1800 0.0
0.0
280
1520
TAS Assembly 3200 1800 0.0 900
* Measured from either end of a part or assembly.
TIS Review13 Dec. 2000
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SAFETY - Surface Temps
TAN -
Operational
Bakeout
TAS -
Operational
Bakeout
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Bill ElliottIR ABSORBER STATUS 18
TAN surface temperature at ultimate luminosity is less than the 57 °C ASTM C-1055 requirement
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 19
SAFETY - SEISMIC STABILITY
TAN Safety & Lifting
IR Absorber EDR13 July 2000, CERN
J.H. BercovitzTAN Design 30
• TAN meets CERN seismic requirements as designed, and LBNL seismic requirements with the addition of temporary extra bracing.
• Shielding surface temperature during bakeout will be approximately 75° C.
Temporary personnel barriers will be required to protect against burns.
The exposed end of the absorber will be covered by a blanket.
•Lifting
•The 30-tonne TAN assembly is to be lifted by four 11000 kg hoist rings from the lower base plate using a spreader bar.
•The longitudinal clear space under the TAN is 2.4 m, sufficient for the
2.3 m long transfer carriage.
•Individual TAN components all have masses less than 5000 kg.
See LBNL Eng. Note M7909 for details
TAN Safety - Seismic
IR Absorber EDR13 July 2000, CERN
J.H. BercovitzTAN Design 31
TAN Safety - Seismic (cont.)
IR Absorber EDR13 July 2000, CERN
J.H. BercovitzTAN Design 22
To overturn in an earthquake, the lateral acceleration must exceed gravity*[(base/2)/height]
If the vertical acceleration of the earthquake is .11 g, then the restoring force due to gravity comes from the remaining .89 g.
Currently, max. allowable lateral acceleration = .89*200.5/534.2 = .334 g See sketch, above.
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 23
Lifting: - The 3200 kg TAS is designed to be lifted with a single 4200 kg rated Hoist Ring. Hoist Ring is to be proof tested to 6300 kg (150% of rated load) and thereafter non- destructive testing is to be performed.Seismic: - LBNL seismic criteria are, greater than CERN criteria so satisfy CERN requirements, and are:
0.70 g horizontal0.35g vertical
TAS - Safety Issues
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 24
Seismic continued: - Here the worst case is when the TAS is assembled in theTas Assembly Fixture with the highest stress condition in thevertical support rods:
Loading Stress(MPa) Half the absorber weight 126 Bending load 430 Maximum operational load 556
Additional vertical load due to 0.35g 44 Max. load under seismic conditions 600 Stressproof: Ultimate strength 889 Mpa
Safety Factor 1.5 based on ultimate strength
TAS - Safety Issues (continued)
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 25
BAKEOUT: - During vacuum bakeout the TAS will be held at 200 C for a minimum of 24 hours. At LBNL: The TAS will not be surrounded by shielding, therefore it will be insulated with blankets and personnel barriers will be placed around the bakeout area. At CERN: Barriers need to be erected around the TAS to prevent access to the TAS during bakeout. The surrounding ATLAS shielding will only rise to 35 C and the surrounding CMS shielding will rise to 75 C during a typical 24 hour heatup and 24 hour bakeout cycle.
TAS - Safety Issues (continued-2)
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 26
Implementation of Safety MoU
MoU Milestones Completed:
Completed Engineering Reviews:Engineering Design Review: 13 July 2000 Production Readiness Review: 2 Nov. 2000
Planned LBNL Internal Safety Reviews
Building 60 Crane: TAN is over Crane rated capacity
Vacuum Bakeout : Personnel safety
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 27
• Engineering Design Review: July 13, 2000 at CERN
• Design and Engineering of the TAN and TAS presented– Design is Complete, proceed to final details necessary for fabrication
– TAN
• 16 detailed LBNL/CERN action items– Redesign the Pair of Pants transition zone to eliminate the vacuum pumping
slots, allow NEG coating
– TAS
• 21 detailed LBNL/CERN action items– LBNL required to build test stand for the jacks/fiducial checkout
– Test stand to simulate slopes in the LHC tunnel
IR ABSORBERS - Engineering Design Review
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 28
DETAILS PRESENTED
• PROCUREMENT PLAN
– Internal and external fabrications, vacuum beam tube methodology
• FABRICATION PLAN
– LBNL site location, Lead technician, Testing resources, Alignment resources
• RESOURCE LOADED SCHEDULE
• ACCEPTANCE PLAN
• QA PLAN
• PROPOSED ENGINEERING DOCUMENT FILE
The Production Readiness Review (PRR) for the IR ABSORBERS was held on 2 Nov. 2000
TIS Review13 Dec. 2000
Bill ElliottIR ABSORBER STATUS 29
PRR RECOMMENDATIONS:
• Fabricate a first article TAN vacuum chamber ASAP
• Schedule a Pre-Assembly Review in March‘01 before start of assembly– Final checkout of QA and Acceptance plan
• Logistics– Develop a logistics plan for tracking parts
– Consider additional staff for logistics tracking, QC/QA work
• Schedule– Examine a 1+3 production method instead of 4 units in parallel
– Incorporate resource constraints into schedule (30 ton crane, test equipment, floor space, technicians)
IR ABSORBERS - PRODUCTION PLAN